nasa space launch systemadvanced developed opportunities

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National Aeronautics and Space Administration

www.nasa.gov/sls

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NASA Space Launch SystemAdvanced Developed Opportunities

Chris Crumbly, ManagerSLS Advanced Development Office

www.nasa.gov/sls

MarsInternationalSpace Station

LagrangianPoint L2

Near-Earth Asteroid

Moon

70 t

CommercialPartners

130 t

The Future of Exploration

www.nasa.gov/sls

100sof Miles

Human Space Operations

Human Space Exploration

1,000sof Miles

10,000sof Miles

100,000sof Miles

1,000,000sof Miles

10,000,000sof Miles

100,000,000sof Miles

Earth

Europa

Robotic Science

8510_ADO_Activities_2

www.nasa.gov/sls

SLS 70 metric ton Expanded View

Launch Abort System

Launch Vehicle/Stage Adapter

Core Stage and Avionics

RS-25Engines (4)

Service Module

Solid Rocket Boosters (2)

Interim Cryogenic Propulsion Stage

(ICPS)

Encapsulated Service Module Panels

Crew Module

Orion Multi-PurposeCrew Vehicle (MPCV)

Spacecraft Adapter

MPCV/Stage Adapter (MSA)


www.nasa.gov/sls

Exploration Mission One (EM – 1)


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07/2014‐15 Test Main Engines, Boosters , & Core Stage Structure

07/2015 Complete the SLS Critical Design Review

06/2016 Assemble the Core Stage Assembly and Test Fire

07/2017 Stack the SLS Vehicle

12/2017 Transport SLS from the VAB to the Launch Pad

04/2014 Complete Manufacturing Tooling Installation

WHAT

’S NEX

T Building to Exploration Mission-1 (EM-1)

07/2013 Completed First Confidence Barrel Section Welding

09/2011 Tested Booster Development Motor

10/2011 ‐ 12/2013 Tested SLS Wind Tunnel Models

December 2017 EM-1 Launches from KSC

11/2013 Conducted Adaptive Augmenting Control Flight Test

12/2013 Completed LOX Forward Dome Manufacturing Demo

1/2014 Conducted Avionics “First Light” in Integration Facility

07/2013 Competed Preliminary Design Review

07/2012 Delivered RS‐25 Engines to Inventory

02/2014 Shipped Multi‐Purpose Crew Vehicle Stage Adapter for EFT‐1

10/2013 Completed Thrust Vector Control Test

ACCOM

PLIS

HM

ENTS


www.nasa.gov/sls

Building on the U.S. Infrastructure

Working with Industry Partners to Develop America’s Heavy-Lift Rocket

Launch Abort System

70 t320 ft

130 t384 ft

Orion Multi-Purpose Crew Vehicle (MPCV)

• Lockheed Martin

INITIAL CAPABILITY, 2017–21 EVOLVED CAPABILITY, Post-2021

Fairings (27.5’ or 33’)•Right-sized for the payload•Received industry input in FY13

Core Stage Engines• Using Space Shuttle Main Engine inventory assets• Building on the U.S. state of the art in liquid oxygen/hydrogen• Initial missions: Aerojet Rocketdyne• Future missions: Agency is determining acquisition strategy

5-Segment Solid Rocket Boosters•Upgrading Shuttle heritage hardware

•ATK

Interim CryogenicPropulsion Stage•Early flight certification for Orion•Flexible for a range of payloads•Boeing

Core/Upper Stage•Common design, materials, & manufacturing•Boeing

Avionics• Builds on Ares software• Boeing

Evolutionary Path to Future Capabilities• Minimizes unique configurations• Allows incremental development• Advanced Development contracts

awarded in Fiscal Year 2013 (FY13)

RS-25

Upper Stage•Commonality with Core Stage•Optimized for Mission Capture

Advanced Boosters• Competitive opportunities for affordable upgrades

•Risk-reduction contracts awarded in FY13


www.nasa.gov/sls 8510_ADO_Activities_7

www.nasa.gov/sls

Advanced Booster Research and Development

Dynetics/Aerojet Rocketdyne

AerojetRocketdyne

Northrop Grumman

ATK

Advanced Booster Engineering Development Risk Reduction (ABEDRR)

Program Description: Reduce risks leading to an affordable advanced booster that meets evolved capability requirements of SLS, and enable competition by mitigating targeted advanced booster risks to enhance affordability


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Aerojet Test Rig

ATK Test Motor

ABEDRR 2013 Accomplishments

Accomplishments for 2013:• Aerojet LOX/RP Engine: Developed system requirements and initiated

preliminary design

• ATK Advanced Booster Performance, Reliability and Affordability:(1) Propellant liner insulation (PLI): tailored liner formulation; tested PLI

bondline;(2) Case damage tolerance: released drawings for 92-in composite

case;(3) Nozzle flex bearing: released drawings of assembly and primary

components;(4) Avionics and controls: defined test methods; assessed actuator

sizing;(5) Static fire test: developed test plan and built igniter

• Dynetics Modernized F-1 Engine and Cryotank Cost Risk Reduction:(1) F-1B engine: hot-fired heritage gas generator (GG); produced F-1

GG injector; completed PDR for power pack assembly and F-1Bmain combustion chamber;

(2) Cryotank structures: completed final design review and released alldrawings; tested schedules for welding domes to dome/tank endrings

• Northrop Grumman Composite Common Bulkhead Tank: Completedcomposite demonstrator design review, held kickoff for test fixture build,built out-of-autoclave test panels with <1% void content

Dynetics F-1B MainCombustion Chamber

Northrop GrummanTank Demonstrator


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Al 2195 T8 GoreDevelopment:

Martin Volz

Objective: Develop manufacturing process formaking gore panels fromaluminum lithium alloy 2195,to achieve weight savings for potential SLS Block 1B. Optimize heat treatment and stretch parameters for thickerpanels.

Accomplishments:• Completed heat treatment

and gore stretching Al 2195 plates of 0.525“ and 0.75”thickness

• Completed tensile strengthand fracture toughness testing of 0.525" and 0.75”gores at roomtemperatures

• Verified improvedmechanical properties ofannealed panels

NDE of Selective Laser Melting Materials:

David Brown

Objective: Characterizenon- destructive inspection performance on powderbed fusion materials foradditive manufacturing(AM) such as selectivelaser melting (SLM)

Accomplishments:• Identified materials

and developed specimens for NDE

• Reviewed limitations ofNDE for AM parts

• Determined thatComputed Tomography (CT) appears to be best method for SLM parts;work remains for planardefects

Cryoinsulation Development: Alison Protz

Objective: Developcloseout processes forlow Global Warming Potential (GWP) foam insulation, and develop/characterize zeroGWP materials. Develop S-180 Manual Spray Foam asrisk mitigation for SLS Core Stage.

Accomplishments:• Completed process

development and specsfor the S-180 manualspray foam

• Wrote manual foamsprayer organizationalwork instruction (OWI)

• Accomplished faband testing of reformulated foam specimens

Chromium VI Free PrimerDevelopment:

Michael Alldredge

Objective: Evaluatecorrosion protectioncapability of multiple commercially- availablehexavalent chromium-free non- hazardousprimers for cryogenic applications

Accomplishments:• Solicited industry for

potential primer candidates

• Performed salt fog/corrosion and cryoflextesting

• Selected 4 primer candidates out of 13 forfurther testing in second phase of project

Low-ProfileDiffuser (LPD):

Mike Martin

Objective: Develop a diffuser concept toreplace existing types witha high performing, low profile design to enablemore propellant capacity and increase SLS performance

Accomplishments:• Used CFD methods to

design LPD• Completed machine

shop work for LPD• Developed test

procedures• Continued CFD analysis

for LPD and Boeingdiffuser to predictperformance

In-House Tasks (Keith Higginbotham)

Space Launch System AdvancedDevelopment Office (SLS–ADO)


www.nasa.gov/sls

SLM PropulsionHardware:

Jason Turpin

Objective: Design,fabricate, and hot fire test an Integral Valve/Injector that is built using AM. Build partnership with Air Force fordevelopment of technologiesthat are synergistic with both NASA SLS and Air Forcegoals. Advance use ofadditive manufacturing (AM) technology for turbomachinery.

Accomplishments:• Completed fabrication,

water flow and hot fire testing of 28-element injector

• Completed fab ofinducer, shrouded impeller,and shrouded turbine

Advanced Passive Avionics Cooling:

Jeff Farmer

Objective: Develop and testadvanced passive thermalcontrol techniques to assess performance and affordability. Provide enhanced avionics cooling benefits for SLSbaseline and upgrades.

Accomplishments:• Completed survey of two-

phase cooling technologiesand identified concepts for SLS application

• Established designrequirements for passiveheat rejection throughpassive sublimator drivencoldplate

• Received hardwarebased on findings ofPhase 1 studies; obtained test area

High Voltage Electronic Parts:

Trent Griffin

Objective: Obtain high voltage electronic parts and conduct low-cost mechanical, electrical and environmental testing.Compile constructionanalysis of these parts and a documented qualificationpath for use on SLS futureTVC upgrade.

Accomplishments:• Completed construction

analysis• Received off-board

parts and materials• Completed circuit

boards• Inspected & removed rod

end and roller-screwmechanism

GH2 Sensor Development: James Currie

Objective: Deliverflight ready gaseous hydrogen (GH2) detectionsensors operable for useon SLS Block 1A. Produce stand-alone leak detection systems with minimal size,weight, and powerconsumption.

Accomplishments:• Completed

electromagnetic interference/ compatibility (EMI/EMC)and ESDtesting

• Completed randomvibration screening

• Completed sensorcalibration

• Completed algorithmfor both GN2 and air

Fluid Structures Coupling Damper:

Rob Berry

Objective: Assessfeasibility and effectivenessof fluid structures coupling damper technology to control vehicle lateral modes, mitigate slosh,and SLS- unique axial mitigation

Accomplishments:• Developed prototype

design for mitigating vehicle axial modes

• Demonstrated axial mitigation for SLS through testing

• Derived lateral equations and correlated with test

• Anchored analytical abilities to properly capture physics

In-House Tasks (continued)



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In-House Tasks (continued)

Advanced Telemetry System:Patrick Campbell and Bill Hopkins

Objective: Investigate the use of advanced modulationtechniques that allow (1) more data to be transmitted in achannel and (2) the use of fewer radios. Since SLS will usetraditional RF telemetry systems to transmit data to theground, high data rate requirements will necessitate multipleradios or high-bandwidth channels. Cost and spectrumconstraints could make this approach difficult. This projectcould provide the telemetry solution.

Accomplishments:• Received the receiver/modulator hardware capable of up

to 8 Phase Shift Keying (PSK) modulation and low-densityparity check (LDPC) forward error correction

• Evaluated spectrum and developed RF architecture

Accomplishments:• Designed, fabricated, and tested two orthogrid 8-ft diameter

cylinder test articles• Designed two isogrid 8-ft diameter cylinder test articles• Completed buckling analysis• Improved knockdown factors for combined mechanical,

thermal, and pressure loads

Shell Buckling Knockdown Factors:Mark Hilburger

Objective: Develop and validateanalysis-based shell bucklingknockdown factor (KDF) updates forSLS- specific orthogrid and isogridstiffened metallic cylinders. Seekreductions in design cycle time andreworks, enhance safety/reliability, and enable significant mass savingspotential in the SLS core stage (>3-4mt).



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In-House Tasks (NESC Funded/Managed)

Advanced Integrated Combustion

Stability Capability:Kevin Tucker

Pyroshock Characterization of Composite Materials:

David Ordway

Objective: Support potential useof composites in the evolved SLS vehicle; evaluate materials toinsure they can withstand launch loads and pyroshock-induced stresses during stage separation

Accomplishments:• Completed pyroshock testing

for solid and honeycombcomposite panels

• Developed algorithms for exportof data for statistical analytical tools

• Used output from the algorithmsas input for the statisticalanalyses

Booster Interface Load Analysis:

Greg Brauckmann

Accomplishments:• Completed pre-test numerical

simulations• Completed wind tunnel test• Supported Buffet Loads

Mitigation Team; provided CFDresults to guide testing options

• Briefed CFD and testing results to chief engineer

• Provided buffet simulation resultsto SLS Aero team

Block IAAdvanced Booster Composite Case/

Internal Insulation:Jessica Chaffin

Objective: Evaluateprocessing through tensile strength, impact peel strength, and waterburst testing. Develop NDE damage standards; determine NDEmethods best suited to large-scale loaded motors. Evaluate high-energy propellants.

Accomplishments:• Evaluated 3 propellant types

through testing for hazards, burnrate, tensile properties; selected 2 propellant candidates or scale-up

• Manufactured and scale-upManufactured and completedNDE for 38 oven cured bottles

• Determined applicability of NDEmethods for composite bottles

Objective: Researchand optimize boosterinterference loads for advanced SLS booster configurations. UseCFD tools with windtunnel experiments to characterize booster interference effects.


Objective: Advance the predictive capability of tools used in SLS combustion stability assessments;facilitate identification/mitigation of combustion instabilities during SLS propulsion system development; reduce development costs

Accomplishments:• Completed CFD simulations

of gas centered swirl coax injector elements

• Identified engineering tool needsfor higher- fidelity inputs & model

• Completed scaling of hydrocarbon boost element; held CDR for testing of this element

Regions of interest for interference


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University Grants (Mindy Nettles)

High Electrical Density Device Survey:

Auburn

Development of AtomizationModels for LiquidRocket Injectors:

Florida

Improved Friction Stir Welds Utilizing On-line Sensing

of Weld Quality:LSU

Objective: Create an on- weldquality sensing system to aid the manufacturing process of friction stir welding, and expedite the process todetermine defect- free weldingparameters

Accomplishments :• Determined that process variables

are coupled, and that changing onevariable alters entire weld

• Correlated initial data with theoretical models

• Determined that x-ray data and Phased Array Ultrasonic Testing(PAUT) results agree

• Proved that PAUT is best choice for on-line detection

Supersonic Film Cooling Numerical Simulations:

Maryland

Objective: Develop adetailed understanding of film cooling fluid dynamics so that predictive CFD approaches can be developed

Accomplishments:• Compared measured to

simulated wall heat flux• Developed high frequency pitot

probe for measuring velocity fluctuations insupersonic stream

• Developed high intensity pulsed light source for Schlieren images

• Validated simulation for film cooling flows


Objective: Conduct an assessment and develop databaseof commercial energy storagedevices, to meet future SLS power requirements and minimizemass/volume

Accomplishments:• Completed survey of

commercially available batteries, dielectric capacitors, and supercapacitors, and determined critical parameters

• Surveyed newly developedtechnologies

• Assessed new dielectric composites-based energystorage devices

Objective: Deliverimproved high-fidelity design toolfor SLS liquid engine injectors, help improve combustion efficiency of the SLS liquidpropulsion systems, and predictcombustion instabilities

Accomplishments:• Completed stochastic modeling

of subcritical primaryatomization for steady case

• Integrated primaryatomization stochasticmodel into Loci-CHEM


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Transient Combustion Processes in Rockets: Michigan and Stanford

Cavitation Challenges in Turbopump Inducers: MIT

Gas Turbine Lab

Enhancements for HybridRANS-LES: Mississippi

State

Objective: Achieveimprovement to hybrid Reynolds Averaged Navier Stokes/Large Eddy Simulation (RANS/LES) CFDmodeling, for practical solutions to problems ofinterest to SLS

Accomplishments:• Implemented a kinetic-

energy- consistentalgorithm into Loci-CHEM

• Implemented a high-resolution gradient calculation method intoLoci-CHEM

• Delivered updatedCHEM version to NASA;further testing and validation ongoing

Aluminum/Alumina Carbon Interactions in

Rockets: Penn St.

Objective: Develop fundamental understandingof Al/Al2O3/carbon thermochemical reactionslikely to be important forSLS motor applications by performing basic experiments

• Accomplishments: Conducted CO2 laserheating experimentsfor Al/Al2O3/carbon using graphite crucible

• Observed general behavior with temperatureusing video, along with gas sampling and post-test sample analysisperformed on select test samples

Acoustic Emission-Based Health

Monitoring of SLSStructures: Utah

Objective: Develop a structural health monitoringsystem for SLS structures. Increase reliability of thestructure by accuratelyidentifying location and typeof damage due to impactsduring transportation and assembly

Accomplishments:• Examined sensor

response on panels due to actual and simulatedimpacts

• Evaluated acousticemission sensors

• Conducted impacts atdifferent temperaturesand evaluated location algorithm

• Continued work onlocation estimation

University Grants (continued)


Objective: Accomplishcomputational and experimental research todevelop validated simulationtechniques for accurateprediction of unstablecombustion processes inrocket engines

Accomplishments:• Brought planar laser-induced

fluorescence (PLIF) systemonline for diagnostics; made progress on particle imagevelocimetry (PIV) system

• Worked toward PIV/ PLIFsystem with wall temperature and chamberpressure measurements

• Developed combustion model with flame- normalheat-loss effect

Objective: Mitigate higherorder cavitation in SLSturbomachinery to improverocket engine reliability and performance. Develop newmethodology for quicklyassessing inducer designsto suppress cavitation

Accomplishments:• Defined new turbopump

inducer blade passagemodel and establishedbody force methodology

• Designed inducer andverified performance agreement with SSME

• Computed cavitation performance of inducer


www.nasa.gov/sls

Areas of Common Interest

Affordable UpperStage Engine Program Studies

American Kerosene Engine Studies

Selective Laser Melting Materials Characterization


Common Needs

BoosterHydrocarbon Engines

AdvancedManufacturing

Opportunities

Advanced UpperStage Engines

www.nasa.gov/sls

Program Description:Develop affordable upper stage engine as replacement for RL10, providing a new capability benefiting muliple stakeholders in the US launch industry, including NASA and U.S. Air Force

MSFC Role:Program Management (Brian Barley)

Accomplishments for 2013 include:• Aerojet Rocketdyne Next Generation Engine System Study: Finalized

initial major subsystem requirements documents; completed powerbalance analyses for AUSEP; finalized figure of merit weighting toemphasize affordability

• Aerojet Rocketdyne Engine Trade Study: Evaluated all planned cycles andcreated power balance models for candidate architectures; created utilityfunction balancing factors such as cost, reliability, performance

• Exquadrum Dual-Expander Aerospike Engine: Completed trade studies toidentify optimum engine configuration; completed conceptual design ofengine; developed modular thrust cell design

• Moog High Pressure LOX Control Valve: Completed valve design based onflow/pressure parameters from potential upper stage developers; completedPDR; produced valve body using additive manufacturing at MSFC

• Northrop Grumman Liquid Engine Requirements Study: Completedbroad engine system trades; initiated detailed trades and design studies;selected point of departure engine system concept; performed thrustchamber trades

• Results being analyzed and integrated by Booz Allen Hamilton with final report due spring 2014

Affordable Upper Stage Engine Program


www.nasa.gov/sls

American Kerosene Engine Studies

• NASA and USAF Space and Missile Systems Center (SMC) have partnered to study potential synergy on an American Kerosene Engine. Multiple partners involved:

• Aerojet Rocketdyne: Looking at multiple concepts for AKE opportunities, based on SLS ABEDRR efforts. (Potential study on RD-180 co-production put on hold.)

• Northrup Grumman: Studying concepts for hydrocarbon aerospike engine, proposed for possible utilization for SLS advanced boosters.

• Georgia Tech University: Performed study on oxygen-rich staged combustion engine technology. Results are being presented at this conference.

• ABEDRR contractors to study extensibility of SLS Advanced Booster liquid engine concepts to AF EELV architectures

• Key study objectives –• Technical feasibility, DDT&E plans and risks• Cost and schedule estimates

• Results being analyzed and integrated by Booz AllenHamilton and Onyx Aerospace with final report due spring 2014


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AKE Study Timeline


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Selective Laser Melting Road to Flight


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Selective Laser Melting Examples


nasa space launch systemadvanced developed opportunities

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